Addendum to the Assembly and Operating Instructions

Transcription

1 Drive Technology \ Drive Automation \ System Integration \ Services *235971_317* Addendum to the Assembly and Operating Instructions Industrial Gear Units X.. Series Helical and Bevel-Helical Gear Units Oil-Water Cooler for Pressure Lubrication /OWP Edition 3/ /EN

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3 Table of contents Table of contents 1 Important information Oil-water cooler for pressure lubrication /OWP Structure/function Wiring diagram (schematic illustration) Installation/assembly Notes on checking the oil level Startup Inspection/maintenance Malfunctions Permitted lubricants /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 3

4 1 Important information 1 Important information INFORMATION This addendum describes amendments to the Oil-Water Cooler operating instructions. Observe the additional information specified in this document. This document does not replace the detailed operating instructions /EN 3/217 4 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

5 Oil-water cooler for pressure lubrication /OWP Structure/function 2 2 Oil-water cooler for pressure lubrication /OWP 2.1 Structure/function Structure An oil-water cooling system can be used if the thermal rating of the naturally cooled gear unit or cooling using a fan on the input shaft is not sufficient. The prerequisite for using an oil-water cooling system is that appropriate cooling water is available on site. INFORMATION Contact SEW EURODRIVE if you use chemically aggressive cooling media such as brackish water or salt water. The following information applies for gear units with pressure lubrication. Also refer to the operating instructions of the cooling system manufacturer. SEW EURODRIVE uses 2 types of oil-water coolers: A plate heat exchanger is used for the oil-water cooling system OWP 5/15/25. A shell and tube heat exchanger is used for the oil-water cooling system OWP 1/2/3/4/5/6/ General information The cooling system including the cooling circuit piping but without electrical wiring is mounted directly to the gear unit at factory. Optionally, the cooling system can be delivered on a mounting frame for separate mounting but without electrical wiring and piping to the gear unit. The standard delivery of the basic cooling system includes: Pump with directly connected asynchronous motor (pump always running) Oil-water heat exchanger Oil filter with filter element and electrical/optical maintenance indicator Pressure switch that monitors the pump pressure. Warning or switch-off signal when the oil pressure reaches <.5 bar Temperature switch/ntb with trip point for monitoring the cooling group, i.e. warning or gear unit shutdown at oil temperature > 9 C Optional accessories The cooling system can be equipped with the following components as an option: Oil filter as duplex filter The oil filter is available as single filter or duplex filter. For pressure lubrication sys-tems, a single filter is included as standard /EN 3/217 Flow rate sensor Manometer Thermometer PT1 temperature sensor Thermostat valve Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 5

6 2 Oil-water cooler for pressure lubrication /OWP Structure/function Function Observe the following control information for the individual components. Pump The driving motor of the pump has to be switched on 1 s prior to gear unit startup and is always running during operation of the gear unit. Oil-water cooler The gear unit is cooled by an oil-water cooler. SEW EURODRIVE recommends using the cooling water at a temperature of 6 C or higher. An optional thermostat valve can be used for controlling the cooling system if the user is required to adjust the switching temperature. Temperature switch /NTB The temperature of the plant is monitored via a temperature switch with a defined switching point. At T > 9 C STOP GEAR UNIT/WARNING PT1 temperature sensor (optional) Optionally, a PT1 temperature sensor instead of a temperature switch/ntb can be used to control the cooling system. The evaluation of the temperature signal and the controlling of the operator's switching devices is performed by the operator's control. At T > 9 C GEAR UNIT STOP / WARNING Filter The filter is monitored visually by a pressure deviation indicator, and electrically by a pressure deviation monitoring device. When m p > 2.2 bar WARNING (clean filter) Pressure switch The pressure switch requires a 1 s delay. Check valve The check valve opens at a pressure of 1 bar /EN 3/217 6 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

7 Oil-water cooler for pressure lubrication /OWP Structure/function Interlocking specifications Enabling of the gear unit Gear unit enable if the following conditions are met: Oil pressure p.5 bar (startup delay of 1 s) Oil temperature T < 9 C STOP gear unit/warning Gear unit STOP/warning if one of the following conditions is met: Oil temperature T > 9 C Oil pressure p <.5 bar /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 7

8 2 Oil-water cooler for pressure lubrication /OWP Wiring diagram (schematic illustration) 2.2 Wiring diagram (schematic illustration) The wiring diagrams show a possible setup of the control for the cooling system Control circuit with optional temperature switch/ntb L1 F1 F2 Emergency off S1 K5 Option S2 K5 P p <.5 bar p >.5 bar ϑ T2 opens at ϑ OIL > 9 C K1T 1 s K4 K5 K1T K1 K2 K3 Temp. signal to main motor control: Warning/switch-off N Main contactor "On" for main motor control Time-delay relay Control circuit with optional PT1 temperature sensor L1 F4 F5 Emergency off Option S2 S1 K5 P p <.5 bar K5 p >.5 bar customer control PT1 K1T 1 s K4 K5 K1T K1 K2 K3 At ϑ OIL > 9 C Temp. signal to main motor control: Warning/switch off N Main contactor "On" for main motor control Time-delay relay /EN 3/217 8 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

9 Oil-water cooler for pressure lubrication /OWP Wiring diagram (schematic illustration) Main circuit L1 L2 L3 F3 F4 K4 K5 Signal of: contactors K1, K2 Option: Signal of contactor K3 via temperature switch type NTB (NC contact) or PT1 temperature sensor Warning/switch-off M1 Main motor control M 3 M2 M 3 PE Main motor Pump motor /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 9

10 2 Oil-water cooler for pressure lubrication /OWP Installation/assembly 2.3 Installation/assembly INFORMATION First adhere to the operating instructions of the oil supply system manufacturer Installation and connection information The cooling system is mounted directly on the gear unit as standard. Optionally, the cooling system can be delivered as a complete unit on a mounting frame for separate mounting but without electrical wiring and piping. Ensure that the installation site is subject to minimal vibrations and is a maximum distance of 1 m from the gear unit. Install the cooling system at the same level as the gear unit or lower. If this is not possible, contact SEW EURODRIVE. INFORMATION For the dimensions of the cooling system and detailed technical data, refer to the operating instructions of the cooling system manufacturer Mechanical connection Connect the cooling system to the gear unit and the water supply according to the designations observing the country-specific regulations. Adhere to the following basic conditions when connecting the cooling system to the gear unit: Do not reduce the specified cable cross sections. It is important that you choose the correct wall thickness and material when selecting pipes, hoses and screw fittings. Preferably use screw fittings with non-metallic gaskets /EN 3/217 1 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

11 Oil-water cooler for pressure lubrication /OWP Installation/assembly Electrical connection Observe country-specific regulations during the electrical connection. With the standard design, connect the following components: Pump motor Temperature switch/temperature sensor Pressure switch Maintenance indicator of the oil filter Observe the following information. Make sure that the pump rotates in the correct direction. Observe the motor data sheet. The pump motor has to be switched on 1 s prior to gear unit startup and is always running during operation of the gear unit. The pressure switch issues a warning signal when the pressure falls below.5 bar. If a temperature switch/ntb is used, it must be integrated in the circuit in a way that Either a warning signal is activated or the main drive is switched off at the switching point (at 9 C oil temperature). If a temperature sensor/pt1 is used, it must be integrated in the circuit in a way that Either a warning signal is issued or the main drive is switched off when the oil temperature reaches 9 C. The maintenance indicator of the filter indicates when the filter element needs to be replaced. When using options: Connect the flow rate sensor to the customer-provided control Limit temperature for start-up of the oil supply system To ensure a correct function of the oil supply system the gear unit oil must have at least the minimum oil viscosity. The viscosity depends on the used oil, and on the oil temperature in the oil pipes/hoses and in the oil pump. Observe chapter "Permitted lubricants" ( 2 18). When the oil supply system is used at low ambient temperatures, it may be required to adjust the oil supply system. Contact SEW EURODRIVE, if required /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 11

12 2 Oil-water cooler for pressure lubrication /OWP Installation/assembly Cooling media INFORMATION Note that the service life, the efficiency, and the maintenance intervals of the heat exchanger depend to a great degree on the quality and ingredients of the cooling medium. Special measures have to be taken when using sea water or brackish water. Contact SEW EURODRIVE. Observe the information in the supplied manufacturer s documentation regarding water quality. Permitted cooling media Water, water/glycol cooling liquids Cooling water temperature and flow rate of oil and cooling water according to the order documents /EN 3/ Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

13 Oil-water cooler for pressure lubrication /OWP Notes on checking the oil level Notes on checking the oil level Using an oil supply system might influence the oil level. The fill quantities specified on the nameplate are guide values and refer only to the gear unit. The mark on the oil dipstick, oil level glass or oil sight glass is the decisive indicator of the correct oil quantity. Observe the chapter "Checking the oil level" in the operating instructions for the gear unit Additionally required gear unit oil The following table shows the lubricant fill quantity which has to be filled into the gear unit additionally for the oil supply system. The information is based on the standard cross section of the pipes for a suction pipe length of 1.5 m and a pressure pipe length of 2.5 m. Size Additional oil quantity in the gear unit in l OWP OWP OWP OWP OWP OWP OWP 4 7. OWP 5 7. OWP 6 1. OWP /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 13

14 2 Oil-water cooler for pressure lubrication /OWP Startup 2.5 Startup Notes NOTICE Improper startup may result in damages to the gear unit or oil supply system. Possible damage to property. Observe the following information. Before startup, check the functionality of the monitoring devices. (Depending on the types of pressure switch, flow monitor, temperature switch/temperature sensor, maintenance indicator etc.) Before taking the gear unit into operation for the first time and after each oil change, run the oil pump at least 1 minutes to ensure that all oil chambers are filled with oil. Switch off the oil pump and control the oil level after a short period of time. Correct the oil level if necessary. An oil heater is mandatory when operating the oil supply system at low ambient temperatures. For further information, refer to chapter "Limit temperature for startup of the oil supply system" ( 2 11). Do not start up the gear unit if the pressure switch is not connected. Note that the pump must run 1 seconds before startup of the gear unit. If there is a risk of frost and the oil-water cooler is not operated for an extended time, drain the cooling water. The user party must provide for the necessary water connections /EN 3/ Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

15 Oil-water cooler for pressure lubrication /OWP Startup Venting the pump WARNING Danger due to leaking and squirting gear unit oil. Serious injury. You must wear safety goggles. Be very careful when you vent the pump. If the pump does not supply oil immediately when the oil supply system starts, do the following: Fill the pump with oil. Vent the pump on the pressure side during start, if possible at the highest point Setting the thermostat valve (optional) The thermostat valve is not preset upon delivery. The system must be set depending on the local conditions by the user during startup or during operation. Set the thermostat valve so that the oil temperature at maximum operating power is within the range specified in the order /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 15

16 2 Oil-water cooler for pressure lubrication /OWP Inspection/maintenance 2.6 Inspection/maintenance INFORMATION First adhere to the operating instructions of the oil supply system manufacturer Inspection and maintenance intervals Adhere to the following inspection and maintenance intervals. Time interval Depending on the operating conditions, at least every 12 months Varying (depending on external factors) What is to be done? Check condition of oil-water cooler, replace filter element if necessary Check all hose pipes for tightness Checking hose pipes NOTICE Hoses and hose pipes are subject to natural aging even if they are properly stored and used. This is why the period of use is limited. The period of use of hose pipes should not exceed 6 years from the date of manufacture printed on them. The operator of the plant is responsible for making sure that hose pipes are replaced at adequate intervals even if they do not show any signs of safety-related defects. Have hose pipes checked by a specialist at least once a year to ensure operational safety /EN 3/ Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

17 Oil-water cooler for pressure lubrication /OWP Malfunctions Malfunctions Fault Possible cause Measure No oil pump suction Air in the pipes Fill the suction line and oil pump with oil Vent pressure pipe on startup Not enough oil in the gear unit Check oil level in gear unit Wrong oil grade in the gear unit Check oil grade (in particular when temperatures are low) Motor not running Check electrical connections Wrong direction of rotation of the motor Change the direction of rotation Delivery rate of oil pump not sufficient Oil circulation clogged Open valves and plugs Wrong oil grade Check oil grade (in particular when temperatures are low) Wrong motor speed Check pump motor speed Negative pressure at pump suction side too high Oil pump very loud Negative pressure at pump suction side too high Increase cross section of suction line Decrease suction lift Increase cross section of suction line Decrease suction lift Avoid distortion of the suction line Avoid reductions in the suction pipes Oil pump delivers froth Not enough oil in the gear unit Check oil level in gear unit Suction line leaking Check screw fittings for leaks Pressure switch does not switch Air in the suction line of the oil pump Pressure switch connected incorrectly Fill the suction line and oil pump with oil Vent the pump at the pressure side Check the connection Pressure switch defective Replace pressure switch Oil pump defective Consult SEW EURODRIVE. Cooling capacity is not reached Cooling water supply closed Check cooling water supply Cooler dirty Clean the cooler /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 17

18 2 Oil-water cooler for pressure lubrication /OWP Permitted lubricants 2.8 Permitted lubricants This chapter describes the permitted lubricants and the permitted temperatures for industrial gear units from SEW EURODRIVE. INFORMATION The standard for viscosity and oil grade is the type of oil that is specified by SEW EURODRIVE in the order (see order confirmation and nameplate). Contact SEW EURODRIVE if you use bio and food grade lubricants or polyglycol oils. Check the compatibility of the greases and oils used. The tables contain the lubricants approved by SEW EURODRIVE. Oils of the same viscosity class from different manufacturers do not have the same characteristics. In particular, the minimum permitted oil bath temperatures are manufacturer-specific. These temperatures are specified in the lubricant tables. The minimum permitted oil bath temperatures depend on the lubrication type used. These temperatures are specified in the lubricant tables. The values correspond to the maximum viscosity of the individual lubricants. The values specified in the lubricant tables apply as of the time of printing of this document. The data of the lubricants are subject to dynamic change on the part of the lubricant manufacturers. For the latest information about the lubricants, visit: Explanation of the structure of the tables and abbreviations Icons CLP CLP HC E Designation = Mineral oil = Synthetic polyalphaolefin (PAO) = Oil based on esters = Mineral lubricant = Synthetic lubricant = Lubricant for the food industry (NSF H1-compliant) Oil Oil = Biodegradable oil (lubricant for agriculture, forestry, and water management) 1) = Lubricants may only be used if service factor F s 1.3 RWDR = Radial oil seal /EN 3/ Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

19 Oil-water cooler for pressure lubrication /OWP Permitted lubricants Explanation of the various lubricants [5] [1] [2] [3] [6] [4] xyz SEW7413 [7] [1] Lowest cold start temperature in C for splash lubrication* [2] Lowest cold start temperature in C for drives with pumps up to a max. oil viscosity of 5 cst* [3] Lowest cold start temperature in C for drives with pumps up to a max. oil viscosity of 2 cst* [4] Trade name [5] Manufacturer [6] Highest oil bath temperature in C. MUST NOT BE EXCEEDED. [7] Approvals *In case of low temperatures, the oil must be heated to the specified minimum temperature, for example by using an oil heater. The maximally permitted oil viscosity per pump type is specified in the following chapter Explanation of the oil supply systems and the oil viscosity In standard design, the motor pump of the cooling system is dimensioned for an oil viscosity of 2 cst. Optionally, a motor pump with an increased suction capacity can be used. This motor pump is dimensioned for an oil viscosity of 5 cst. Contact SEW EURODRIVE, if required /EN 3/217 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 19

20 2 Oil-water cooler for pressure lubrication /OWP Permitted lubricants Lubricant tables The lubricant table is valid when this document is printed. Please refer to for the latest version of the table. DIN (ISO) API CLP ISO,SAE NLGI VG 15 1) VG 22 VG 32 VG 46 VG 68 VG 1 Optigear BM SEW7313 Optigear BM 68 Alpha SP 68 CLP 68 Plus HighGear 68 Mobilgear 6 XP 68 Klüberoil GEM 1-68 N Meropa 68 Carter EP SEW7313 Optigear BM 46 Alpha SP 46 CLP 46 Plus HighGear 46 Mobilgear 6 XP 46 Klüberoil GEM 1-46 N Shell Omala Oil F 46 Meropa 46 Carter EP SEW7313 Optigear BM 32 Alpha SP 32 CLP 32 Plus HighGear 32 Mobilgear 6 XP 32 Klüberoil GEM 1-32 N Shell Omala Oil F 32 Meropa 32 Carter EP SEW7313 Optigear BM 22 Alpha SP 22 CLP 22 Plus HighGear 22 Mobilgear 6 XP 22 Klüberoil GEM 1-22 N Shell Omala Oil F 22 Meropa 22 Carter EP SEW7313 Optigear BM 15 Alpha SP 15 CLP 15 Plus HighGear 15 Mobilgear 6 XP 15 Klüberoil GEM 1 N Meropa Mobil LUBRICATION TO T A L Sh e ll TEXACO FUCHS /EN 3/217 2 Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

21 Oil-water cooler for pressure lubrication /OWP Permitted lubricants 2 The lubricant table is valid when this document is printed. Please refer to for the latest version of the table SHC SHC 626 Klübersynth GEM 4-68 N Omala S4 GX SHC 629 SHC Gear 15 Klübersynth GEM 4 N Omala S4 GX 15 Pinnacle EP 15 Carter SH SHC 63 SHC Gear 22 Klübersynth GEM 4-22 N Omala S4 GX 22 Pinnacle EP 22 Carter SH SHC 632 SHC Gear 32 Klübersynth GEM 4-32 N Omala S4 GX 32 Pinnacle EP 32 Carter SH SHC 634 SHC Gear 46 Klübersynth GEM 4-46 N Omala S4 GX 46 Pinnacle EP 46 Carter SH SHC 636 SHC Gear 68 Klübersynth GEM 4-68 N Omala S4 GX 68 Carter SH SHC 639 SHC Gear 1 Klübersynth EG4-1 FUCHS Mobil LUBRICATION TO T A L Sh e ll TEXACO Unisyn CLP Alphasyn EP 15 Optigear Synthetic X 15 Unisyn CLP Alphasyn EP 22 Optigear Synthetic X 22 Unisyn CLP 22 HighGear Synth Alphasyn EP 32 Optigear Synthetic X 32 Unisyn CLP 32 HighGear Synth Alphasyn EP 46 Optigear Synthetic X 46 Unisyn CLP 46 HighGear Synth Optigear Synthetic X 68 Unisyn CLP 68 HighGear Synth /EN 3/217 ISO,SAE NLGI DIN (ISO) API VG 32 1) VG 68 1) VG 15 1) VG 22 CLP HC VG 32 VG 46 VG 68 VG Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units 21

22 2 Oil-water cooler for pressure lubrication /OWP Permitted lubricants The lubricant table is valid when this document is printed. Please refer to for the latest version of the table. DIN (ISO) API CLP HC NSF H1 E ISO,SAE NLGI VG 68 1) VG 22 1) VG 46 1) VG Cassida Fluid HF 68-2 Cassida Fluid GL Cassida Fluid GL Optileb HY 68 Optileb GT Optileb GT 46 FUCHS +95 Plantogear 46 S LUBRICATION Klüberoil 4UH1-68 N Klüberoil 4UH1-22 N +95 Klüberoil 4UH1-46 N +95 Klüberbio CA /EN 3/ Addendum to the Assembly and Operating Instructions X.. Series Helical and Bevel-Helical Gear Units

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